EP2736636B1 - Method for removing sulfur compounds from gaseous hydrocarbons using catalytic compositions - Google Patents

Method for removing sulfur compounds from gaseous hydrocarbons using catalytic compositions Download PDF

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EP2736636B1
EP2736636B1 EP12728000.6A EP12728000A EP2736636B1 EP 2736636 B1 EP2736636 B1 EP 2736636B1 EP 12728000 A EP12728000 A EP 12728000A EP 2736636 B1 EP2736636 B1 EP 2736636B1
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sulfur
catalyst
catalytic composition
compounds
phase
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English (en)
French (fr)
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EP2736636A1 (en
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Abdennour Bourane
Omer Refa Koseoglu
Zinfer ISMAGILOV
Svetlana YAHNIK
Mikhail KERZHENTSEV
Valentin Parmon
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Boreskov Institute of Catalysis Siberian Branch of Russian Academy of Sciences
Saudi Arabian Oil Co
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Boreskov Institute of Catalysis Siberian Branch of Russian Academy of Sciences
Saudi Arabian Oil Co
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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G27/00—Refining of hydrocarbon oils in the absence of hydrogen, by oxidation
    • C10G27/04—Refining of hydrocarbon oils in the absence of hydrogen, by oxidation with oxygen or compounds generating oxygen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/005—Spinels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
    • B01J23/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
    • B01J23/80—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with zinc, cadmium or mercury
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
    • B01J23/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
    • B01J23/83—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with rare earths or actinides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/90—Regeneration or reactivation
    • B01J23/94—Regeneration or reactivation of catalysts comprising metals, oxides or hydroxides of the iron group metals or copper
    • B01J35/393—
    • B01J35/60—
    • B01J35/613—
    • B01J35/633—
    • B01J35/647—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/03—Precipitation; Co-precipitation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/03—Precipitation; Co-precipitation
    • B01J37/031—Precipitation
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G25/00—Refining of hydrocarbon oils in the absence of hydrogen, with solid sorbents
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G29/00—Refining of hydrocarbon oils, in the absence of hydrogen, with other chemicals
    • C10G29/16—Metal oxides
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/20—Characteristics of the feedstock or the products
    • C10G2300/201—Impurities
    • C10G2300/202—Heteroatoms content, i.e. S, N, O, P

Definitions

  • This invention relates to methods for removing sulfur-containing compounds from hydrocarbons. More particularly, it relates to such methods, using an oxidative and/or adsorptive process in the presence of a newly described catalyst, where the hydrocarbons are in gaseous phase.
  • the European Union has enacted even more stringent standards, requiring diesel and gasoline fuels sold in 2009 and thereafter to contain less than 10 ppmw of sulfur.
  • Other countries are following in the footsteps of the United States and the European Union and are moving forward with regulations that will require refineries to produce transportation fuels with ultra-low sulfur levels.
  • refiners must now choose from processes and/or crude oils that provide flexibility so that future specifications relating to lower sulfur levels may be met with minimum additional capital investment, while using existing equipment.
  • Conventional technologies such as hydrocracking and two-stage hydrotreating offer alternative solutions for production of clean transportation fuels. These technologies are available and can be applied as new grassroots production facilities are constructed; however, many existing hydroprocessing facilities, such as those using relatively low pressure hydrotreaters, represent substantial prior investments and were constructed before these more stringent sulfur reduction requirements were enacted. It is very difficult to upgrade existing hydrotreating reactors in these facilities because of the comparatively more severe operational requirements (e.g., higher temperature and pressure) needed to produce so-called "clean" fuel.
  • Available retrofitting options for refiners include elevation of the hydrogen partial pressure by increasing the recycled gas quality, utilization of more active catalyst compositions, installation of improved reactor components to enhance liquid-solid contact, increase of reactor volume, and improvement of feedstock quality.
  • hydrotreating units installed worldwide, which produce transportation fuels containing 500-3000 ppmw sulfur. These units were designed for, and are being operated at, relatively mild conditions (e.g., low hydrogen partial pressures of 30 kilograms per square centimeter for straight run gas oils with boiling points in the range of 180 °C-370 °C.
  • Sulfur-containing compounds that are typically present in hydrocarbon fuels include aliphatic molecules such as sulfides, disulfides and mercaptans, as well as aromatic molecules such as thiophene, benzothiophene and its long chain alkylated derivatives, dibenzothiophene, and its alkyl derivatives such as 4,6-dimethyldibenzothiophene.
  • Aromatic sulfur-containing molecules have a higher boiling point than aliphatic sulfur-containing molecules, and are consequently more abundant in higher boiling fractions.
  • the light and heavy gas oil fractions have ASTM D85 95 V% points of 319 °C and 392 °C, respectively. Further, the light gas oil fraction contains less sulfur and nitrogen than the heavy gas oil fraction (0.95 W% sulfur as compared to 1.65 W% sulfur and 42 ppmw nitrogen as compared to 225 ppmw nitrogen).
  • Advanced analytical techniques such as multi-dimensional gas chromatography ( Hua R., et al., Journal of Chromatog. A, 1019 (2003) 101-109 ), have shown that the middle distillate cut boiling in the range of 170-400 °C contains sulfur species including thiols, sulfides, disulfides, thiophenes, benzothiophenes, dibenzothiophenes, and benzonaphthothiophenes, with and without alkyl substituents.
  • the sulfur specification and content of light and heavy gas oils are conventionally analyzed by two methods.
  • sulfur species are categorized based on structural groups.
  • the structural groups include one group having sulfur-containing compounds boiling at less than 310 °C, including dibenzothiophenes and their alkylated isomers, and another group including 1, 2, and 3 methyl-substituted dibenzothiophenes, denoted as C 1 , C 2 and C 3 , respectively.
  • the heavy gas oil fraction contains more alkylated di-benzothiophene molecules than the light gas oils.
  • the sulfur content of light and heavy gas oils are plotted against the boiling points of the sulfur-containing compounds to observe concentration variations and trends. See, e.g., Figure 1 of Koseoglu, et al., Saudi Aramco Journal of Technology, 66-79 (Summer 2008 ), incorporated by reference. Note that the boiling points depicted are those of sulfur-containing compounds that were detected rather than the boiling point of the total hydrocarbon mixture.
  • the boiling point of the key sulfur-containing compounds consisting of dibenzothiophenes, 4-methydibenzothiophenes and 4,6-dimethyldibenzothiophenes are also shown in Fig. 1 .
  • the cumulative sulfur specification curves show that the heavy gas oil fraction contains a higher content of heavier sulfur-containing compounds and lower content of lighter sulfur-containing compounds as compared to the light gas oil fraction. For example, it is found that 5370 ppmw of C 3 -dibenzothiophene, and bulkier molecules such as benzonaphthothiophenes, are present in the heavy gas oil fraction, compared to 1104 ppmw in the light gas oil fraction. In contrast, the light gas oil fraction contains a higher content of light sulfur-containing compounds compared to heavy gas oil. Light sulfur-containing compounds are structurally less bulky than dibenzothiophenes and boil at less than 310 °C. Also, twice as much C 1 and C 2 alkyl-substituted dibenzothiophenes exist in the heavy gas oil fraction as compared to the light gas oil fraction.
  • Aliphatic sulfur-containing compounds are more easily desulfurized (labile) using conventional hydrodesulphurization methods.
  • certain highly branched aliphatic molecules can hinder the sulfur atom removal and are moderately more difficult to desulfurize (refractory) using conventional hydrodesulphurization methods.
  • thiophenes and benzothiophenes are relatively easy to hydrodesulfurize.
  • the addition of alkyl groups to the ring compounds increases the difficulty of hydrodesulphurization.
  • Dibenzothiophenes resulting from addition of another ring to the benzothiophene family are even more difficult to desulfurize, and the difficulty varies greatly according to their alkyl substitution, with di-beta substituted compounds being the most difficult to desulfurize, thus justifying their "refractory" interpretation.
  • These beta substituents hinder exposure of the heteroatom to the active site on the catalyst.
  • dibenzothiophene is 57 times more reactive than the refractory 4, 6-dimethyldibenzothiphene at 250°C.
  • the relative reactivity decreases with increasing operating severity. With a 50°C temperature increase, the relative reactivity of di-benzothiophene compared to 4, 6-dibenzothiophene decreases to 7.3 from 57.7.
  • Oxidative desulphurization as applied to middle distillates is attractive for several reasons.
  • mild reaction conditions e.g., temperatures ranging from room temperature up to 200 °C and pressures ranging from 1 up to 15 atmospheres, are normally used, thereby resulting a priori in reasonable investment and operational costs, especially for hydrogen consumption, which is usually expensive.
  • Another attractive aspect is related to the reactivity of high aromatic sulfur-containing species. This is evident since the high electron density at the sulfur atom caused by the attached, electron-rich aromatic rings, further increased by the presence of additional alkyl groups on the aromatic rings, will favor its electrophilic attack as shown in Table 3 ( Otsuki, et al., Energy Fuels, 14:1232 (2000 )).
  • Electron density of selected sulfur species Sulfur compound Formulas Electron Density K (L/(mol.min)) Thiophenol 5.902 0.270 Methyl Phenyl Sulfide 5.915 0.295 Diphenyl Sulfide 5.860 0.156 4,6-DMDBT 5.760 0.0767 4-MDBT 5.759 0.0627 Dibenzothiophene 5.758 0.0460 Benzothiophene 5.739 0.00574 2,5-Dimethylthiophene 5.716 - 2-methylthiophene 5.706 - Thiophene 5.696 -
  • U.S. Patent No. 6,277,271 also discloses a desulfurization process integrating hydrodesulfurization and oxidative desulfurization.
  • a stream composed of sulfur containing hydrocarbons and a recycle stream containing oxidized sulfur-containing compounds is introduced in a hydrodesulfurization reaction zone and contacted with a hydrodesulfurization catalyst.
  • the resulting hydrocarbon stream containing a reduced sulfur level is contacted in its entirety with an oxidizing agent in an oxidation reaction zone to convert the residual sulfur-containing compounds into oxidized sulfur-containing compounds.
  • the oxidized sulfur-containing compounds are removed in one stream and a second stream of hydrocarbons having a reduced concentration of oxidized sulfur containing compounds is recovered.
  • the entire hydrodesulfurized effluent is subjected to oxidation in the Kocal process.
  • U.S. Patent No. 6,087,544 discloses a desulfurization process in which a distillate feedstream is first fractionated into a light fraction containing from about 50 to 100 ppm of sulfur, and a heavy fraction. The light fraction is passed to a hydrodesulfurization reaction zone. Part of the desulfurized light fraction is then blended with half of the heavy fraction to produce a low sulfur distillate fuel. However, not all of the distillate feedstream is recovered to obtain the low sulfur distillate fuel product, resulting in a substantial loss of high quality product yield.
  • Rappas et al., PCT Publication No. WO 02118518 discloses a two-stage desulfurization process located downstream of a hydrotreater. After having been hydrotreated in a hydrodesulfurization reaction zone, the entire distillate feedstream is introduced to an oxidation reaction zone to undergo biphasic oxidation in an aqueous solution of formic acid and hydrogen peroxide. Thiophenic sulfur-containing compounds are converted to corresponding sulfones. Some of the sulfones are retained in the aqueous solution during the oxidation reaction, and must be removed by a subsequent phase separation step. The oil phase containing the remaining sulfones is subjected to a liquid-liquid extraction step. In the process of WO 02118518 , like Cabrera et al. and Kocal, the entire hydrodesulfurized effluent is subject to oxidation reactions, in this case biphasic oxidation.
  • WO 031014266 discloses a desulfurization process in which a hydrocarbon stream having sulfur-containing compounds is first introduced to an oxidation reaction zone. Sulfur-containing compounds are oxidized into the corresponding sulfones using an aqueous oxidizing agent. After separating the aqueous oxidizing agent from the hydrocarbon phase, the resulting hydrocarbon stream is passed to a hydrodesulfurization step. In the process of WO 031014266 , the entire effluent of the oxidation reaction zone is subject to hydrodesulfurization.
  • U.S. Patent No. 6,827,845 discloses a three-step process for removal of sulfur- and nitrogen-containing compounds in a hydrocarbon feedstock. All or a portion of the feedstock is a product of a hydrotreating process. In the first step, the feed is introduced to an oxidation reaction zone containing peracid that is free of catalytically active metals. Next, the oxidized hydrocarbons are separated from the acetic acid phase containing oxidized sulfur and nitrogen compounds. In this reference, a portion of the stream is subject to oxidation. The highest cut point identified is 316 °C.
  • this reference explicitly avoids catalytically active metals in the oxidation zone, which necessitates an increased quantity of peracid and more severe operating conditions.
  • the H 2 0 2 :S molar ratio in one of the examples is 640, which is extremely high as compared to oxidative desulfurization with a catalytic system.
  • U.S. Patent No. 7,252,756 discloses a process for reducing the amount of sulfur- and/or nitrogen-containing compounds for refinery blending of transportation fuels.
  • a hydrocarbon feedstock is contacted with an immiscible phase containing hydrogen peroxide and acetic acid in an oxidation zone. After a gravity phase separation, the oxidized impurities are extracted with aqueous acetic acid.
  • a hydrocarbon stream having reduced impurities is recovered, and the acetic acid phase effluents from the oxidation and the extraction zones are passed to a common separation zone for recovery of the acetic acid.
  • the feedstock to the oxidation process can be a low-boiling component of a hydrotreated distillate. This reference contemplates subjecting the low boiling fraction to the oxidation zone.
  • U.S. Patent No. 5,969,191 describes a catalytic thermochemical process employing a catalyst whose texture is chosen so as to avoid deep oxidation reacting.
  • a key catalytic reaction step in the thermochemical process scheme is the selective catalytic oxidation of organosulfur compounds (e.g., mercaptan) to a valuable chemical intermediate (e.g., CH 3 SH+2O 2 ⁇ H 2 CO+SO 2 +H 2 O) over certain supported (mono-layered) metal oxide catalysts.
  • the preferred catalyst employed in this process consists of a specially engineered V 2 O 5 /TiO 2 catalyst that minimizes the adverse effects of heat and mass transfer limitations that can result in the over oxidation of the desired H 2 CO to CO x and H 2 O.
  • the process described later by the inventors in PCT Application No. WO 2003/051798 involves contacting of heterocyclic sulfur compounds in a hydrocarbon stream, e.g., in a petroleum feedstock or petroleum product, in the gas phase in the presence of oxygen with a supported metal oxide catalyst, or with a bulk metal oxide catalyst to convert at least a portion of the heterocyclic sulfur compounds to sulfur dioxide and to useful oxygenated products as well as sulfur-deficient hydrocarbons and separately recovering the oxygenated products separately from a hydrocarbon stream with substantially reduced sulfur.
  • the catalytic metal oxide layer supported by the metal oxide support is based on a metal selected from the group consisting of Ti, Zr, Mo, Re, V, Cr, W, Mn, Nb, Ta, and mixtures thereof.
  • a support of titania, zirconia, ceria, niobia, tin oxide or a mixture of two or more of these is preferred.
  • Bulk metal oxide catalysts based on molybdenum, chromium and vanadium can be also used.
  • Sulfur content in fuel could be less than about 30-100 ppmw. The optimum space velocity likely will be maintained below 4800 V/V/hr and the temperature will be 50-200 °C.
  • the feed gas contained 1000 ppmw of COS, or CS2, CH 3 SH, CH 3 SCH 3 , CH 3 SSCH 3 , thiophene and 2,5-dimethylthiophene, 18% O 2 in He balance.
  • the formed products (formalin, CO, H2, maleic anhydride and SO 2 ) were monitored by temperature programmed surface reaction mass spectrometry. It was shown that the turnover frequency for COS and CS 2 oxidation varied by about one order of magnitude depending on the support, in the order CeO 2 > ZrO 2 > TiO 2 > Nb 2 O 5 > Al 2 O 3 - SiO 2 .
  • a common catalyst for oxidative desulfurization is activated carbon ( Yu et al., Energy & Fuels, 19(2):447-452 (2005 ), Wu et al., Energy and Fuels, 19(5):1774-1782 (2005 )).
  • the application of this method allows removal of hydrogen sulfide from gaseous fuels at 150°C by oxidation with air ( Wu et al., Energy and Fuels, 19(5):1774-1782 (2005 ) and also sulfur removal from diesel fuels using hydrogen peroxide ( Yu et al., Energy & Fuels, 19(2):447-452 (2005 )).
  • the higher adsorption capacity of the carbon the higher its activity in the oxidation of dibenzothiophene.
  • U.S. Patent No. 4,596,782 to Courty, et al. teaches a catalytic process for producing ethanol and methanol over a Cu-Zn-Al catalyst.
  • the catalyst requires activation via, e.g., reducing conditions and a substance such as H2, CO, or an alcohol, resulting in the reduction of copper oxide to metal copper particles, which are active in the well known Fischer-Tropsch process.
  • EP 2 067 527 A1 relates to a catalyst for carbon monoxide conversion, comprising from 10 to 90 % by mass of a copper oxide ingredient, from 5 to 50 % by mass of a zinc oxide ingredient and from 10 to 50 % by mass of an aluminum oxide ingredient;
  • EP 2 135 673 A1 relates to a catalyst precursor substance containing copper, zinc, and aluminum and exhibiting an X-ray diffraction pattern having a broad peak at a specific interplanar spacing d ( ⁇ ); and Gao et al. in Energy & Fuels, vol. 23, no. 2 (2009-02-19), pages 624-630 relates to hydrotalcite-like compounds derived CuZnAl oxide catalysts for aerobic oxidative removal of gasoline-
  • labile organosulfur compounds means organosulfur compounds that can be easily desulfurized under relatively mild hydrodesulfurization pressure and temperature conditions
  • refractory organosulfur compounds means organosulfur compounds that are relatively more difficult to desulfurize under mild hydrodesulfurization conditions.
  • the desulphurization of the hydrocarbon full stream may occur via one of two reaction routes.
  • a first route the so-called “oxidative process”
  • the sulfur compounds are oxidized, wherein at least a portion of them are oxidized to SO 2 .
  • a second route the so-called “adsorptive process”
  • the compounds are converted to one or more of sulfates, sulfites, and sulfides. Which route is chosen depends upon reaction conditions as well as the type and amount of sulfur compounds in the hydrocarbon fuel stream.
  • the adsorptive route it is necessary to regenerate the catalysts at some point, so as to remove the sulfur compounds adsorbed therein.
  • solution A Cu(NO 3 ) 2 , (0.2 moles), Zn(NO 3 ) 2 (0.07 moles), and Al(NO 3 ) 3 (0.235 moles), were dissolved in 500 ml of distilled water, to form what shall be referred to as "solution A" hereafter.
  • the pH of the solution was 2.3.
  • solution B which had a pH of 13.7.
  • Solution A was heated to 65°C and solution B was added to solution A, at a rate of about 5 ml/minute, with constant agitation, until all of solution B was added.
  • the resulting mixture had a pH of 11.0.
  • a precipitate resulted which was aged, for 6 hours, at 65°C, pH 11.
  • the solution was cooled to room temperature and filtered with a Buchner funnel. Precipitate was washed with distilled water. Analysis showed that nearly all of the Cu, Zn, and Al precipitated out of the solution (99%).
  • the precipitate was then dried at room temperature, for 12 hours, at 110°C.
  • the dried material was dark brown in color. Following drying, it was calcined, at 500°C, for 2 hours.
  • the calcined product contained 36 wt% elemental Cu, 12.1 wt% elemental Zn, 14.2 wt% elemental Al, and 0.02 wt% elemental Na. (In all of the examples which follow, weight percent is given in terms of the pure element, rather than the oxide.)
  • a feedstock stream "1" and a feed of an oxidizing agent "2" are combined, one of reactors 10a or 10b, which are, respectively, oxidation and adsorption reactors.
  • reactors 10a or 10b which are, respectively, oxidation and adsorption reactors.
  • gas stream "4" is removed and transferred to high pressure separation reactor 20, where C 1 - C 4 gases, oxygen, any SO 2 , H 2 S and COS are separated, as is sulfur free steam "9,” which is removed from the reactor.
  • the stream containing the other materials "5,” is then sent to a scrubber reactor "30," where SO 2 and H 2 S are removed, with the remaining, cleaned gas sent for oxidation, while sulfur containing materials are treated to obtain pure sulfur.
  • any of sulfites, sulfates, and sulfides deposit on the catalyst, and the thus treated gas undergoes the same processes that the gas resulting from the oxidation reaction does.
  • the atomic ratio of Cu:Zn:Al was 3:1:2.8.
  • the product had a specific surface area of 94 m 2 /g, pore volume of 0.24 cm 3 /g, and an average pore diameter of 9.5 nm. It exhibited highly dispersed CuO and ZnO, with an X-ray amorphous oxide phase.
  • "X-ray amorphous oxide phase" as used herein means that, when observed via high resolution transmission electron microscopy ("HRTEM"), crystalline particles ranging from 2-10 nm, and usually 2-5 nm, were observed. Lattice parameters were very close to those of spinels, hence the chemical composition, deduced from EDX data, is Cu 0.3 Zn 0.7 Al 2 O 4 .
  • a 500 ml sample of solution A was prepared as was 600 ml of a new solution B, which contained 1 mole of (NH 4 ) 2 CO 3 , at pH 8.7.
  • Solution A was heated to 65°C, and solution B was added gradually to solution A, with constant agitation.
  • the combined solution had a pH of 7.6.
  • Precipitate was dried, as in Example 1, supra, and then calcined at 500°C for 4 hours.
  • the resulting compound was 26.3 wt% Cu, 15.8 wt% Zn, 22.3 wt% Al, and the atomic ratio of Cu:Zn:Al was 1.7:1:3.5.
  • the compound had a specific surface area of 82 m 2 /g, pore volume of 0.29 cm 3 /g, and an average pore diameter of 12 nm. It exhibited an X-ray amorphous oxide phase (Cu 0.45 Zn 0.55 Al 2 O 4 ), and highly dispersed CuO, which contained less than 50% of the total copper.
  • solution B was prepared by combining 47.7 g (0.45 moles) of Na 2 CO 3 , and 18 g (0.45 moles) of NaOH, in 600 ml of distilled water, to produce a solution with a pH of 13.4.
  • Solution A was heated to 50°C, and solution B was added gradually, at a rate of 4 ml/min, with constant agitation.
  • the resulting pH was 10.
  • the resulting product contained 40.5 wt% Cu, 13.3 wt% Zn, 13.8 wt% Al, and 0.47 wt% Na.
  • the atomic ratio of the components Cu:Zn:Al was 3.1:1:2.5.
  • the composition had a specific surface area of 62 m 2 /g, a pore volume of 0.15 cm 3 /g, and an average pore diameter of 8.7 nm.
  • the composition exhibited an X-ray amorphous oxide phase (Cu 0.2 Zn 0.8 Al 2 O 4 ), and a highly dispersed crystal phase which contained most of the Cu.
  • Example 2 The steps of Example 1 were followed, but the precipitate was filtered hot, and without aging.
  • the calcined composition contained 40.2 wt% Cu, 9.7 wt% Zn, 17.2 wt% Al, and 0.22 wt% Na.
  • the atomic ratio of Cu:Zn:Al was 4.2:1:4.3.
  • the specific surface area was 75 m 2 /g, and the pore volume was 0.29 cm 3 /g. Average pore diameter was 12.5 nm.
  • the phase composition was highly dispersed, crystalline phases of CuO, ZnO, and Al 2 O 3 .
  • Example 2 was followed except 5.5 x 10 -4 moles of cerium nitrate were added to solution A. After the precipitate was formed, it was aged for 6 hours at 55°C. Analysis of the calcined composition showed 20.9 wt% Cu, 17.1 wt% Zn, 23.9 wt% Al, and 0.5 wt% Ce. The atomic ratio of Cu:Zn:Ce:Al was 3.0:1:0.01:3.8. The composition had a specific area of 83 m 2 /g, a pore volume of 0.20 cm 3 /g, and an average pore diameter of 10.0 nm.
  • This example parallels Example 5, except the amount of cerium nitrate was increased to 9.5 x 10 -3 moles. Precipitation formation and filtration were carried out at 65°C, for 6 hours.
  • the resulting calcined composition had the following composition: Cu:20.2 wt%, Zn: 15.1 wt%, Al: 20.2 wt%, Ce: 8.5 wt%.
  • Atomic ratios of Cu:Zn:Ce:Al were 1:35:1:0.25:3.2.
  • the specific surface area was 125 m 2 /g, with a pore volume of 0.3 cm 3 /g. Average pore diameter was 8.0 nm.
  • it exhibited an X-ray amorphous oxide phase and a formula of Cu 0.5 Zn 0.5 Al 2 O 4 . It also exhibited a cerium phase with particles not greater than 10 nm in diameter.
  • solution A contained 0.05 moles Cu nitrate, 0.07 moles Zn nitrate, and 0.13 moles Al nitrate, in 500 ml of distilled water, at a pH of 2.6.
  • Solution B contained 53.0 g Na 2 CO 3 (0.5 moles), and 18 g NaOH (0.45 moles), in 600 ml of water, at a pH of 13.7. The solutions were mixed and the resulting precipitate separated, as in Example 1.
  • the calcined composition contained 10 wt% Cu, 20.0 wt% Zn, 21.3 wt% Al, and 0.65 wt% Na.
  • the atomic ratio of Cu:Zn:Al was 0.5:1:2.5, with a specific surface area of 112 m 2 /g, a pore volume of 0.30 cm 3 /g, and average pore diameter of 10.8 nm.
  • the composition exhibited formula Cu 0.33 Zn 0.67 Al 2 O 4 , and the composition also contained a highly dispersed crystalline ZnO phase.
  • solutions A and B were prepared in the same manner as the solutions of Example 2.
  • the resulting calcined product contained 10.0 wt% Cu, 12.1 wt% Zn, 33.8 wt% Al, and 0.05 wt% Na.
  • the atomic ratio for Cu:Zn:Al was 0.84:1:6.7.
  • the specific surface area was 100 m 2 /g, the pore volume 0.35 cm 3 /g, and the average pore diameter was 11.0 nm.
  • the composition exhibited the same X-ray amorphous oxide phase formula Cu 0.4 Zn 0.6 Al 2 O 4 , and there was a ⁇ -Al 2 O 3 phase as well.
  • Solution A contained 0.05 moles Cu nitrate, 0.02 moles Zn nitrate, and 0.45 moles Al nitrate, dissolved in 500 ml distilled water, and have a pH of 2.25.
  • Solution B contained 53.0 g (0.5 m) (NH 4 ) 2 CO 3 dissolved in 600 ml of distilled water. The pH was 8.0.
  • Precipitation, and separation of the precipitate, took place over 4 hours, at 65°C, pH 6.5, to yield a composition containing 13.0 wt% Cu, 4.2 wt% Zn, and 36.5 wt% Al.
  • the atomic ratio for Cu:Zn:Al was 3.1:1:21.
  • the specific surface area was 150 m 2 /g, with a pore volume of 0.45 cm 3 /g, with an average pore volume of 9.5 nm.
  • the observed formula of the composition was ZnAl 2 O 4 and Al 2 O 3 modified by Cu in the form of CuO.
  • solution A contained 0.25 m Cu, 0.07 moles Zn, and 0.20 moles Al in their nitrate form, dissolved in 500 ml of distilled water, at pH 2.3.
  • Solution B contained 53.0 g Na 2 CO 3 (0.5 m), and 12 g NaOH (0.3 m), in 600 ml distilled water, at pH 13.3.
  • Precipitation conditions were those of Example 1, supra, which did not permit total precipitation of Al. In fact, while the precipitation of Cu and Zn was 99% that of Al did not exceed 80%.
  • the resulting composition contained 50 wt% Cu, 25.2 wt% Zn, 7.4 wt% Al, and 0.85 wt% Na.
  • the atomic ratio of Cu:Zn:Al was 2.0:1.0:0.7.
  • the specific surface area was 50 m 2 /g, the pore volume was 0.20 cm 3 /g, and the average pore diameter was 15.2 nm.
  • the formula of the composition was Cu 0.33 Zn 0.67 Al 2 O 4 , with highly dispersed crystalline CuO and ZnO phases.
  • solution A did not contain Al nitrate, but only 0.04 moles Cu, 0.02 moles Zn and 0.14 moles Ce in nitrate form, dissolved in 500 ml of distilled water, at pH 4.2.
  • Solution B contained 15.0 g (NH 4 ) 2 CO 3 and 18.0 g NH 4 HCO 3 in 600 ml distilled water, at a pH of 8.0.
  • the composition contained 6.5 wt% Cu, 3.85 wt% Zn, and 78 wt% Ce.
  • the atomic ratio of components Cu:Zn:Ce was 1.7:1:9.5, and the specific surface area was 85 m 2 /g, with pore volume 0.23 cm 3 /g and average pore diameter of 10.9 nm.
  • the observed composition by XRD was a highly dispersed crystalline CeO 2 phase. Crystalline phases of Cu and Zn were not detected.
  • Tables 4, 5, and 6 present these results: Table 4- Oxidation of thiophene in octane solution Catalyst T °C S Content ppmw O 2 /S GHSV h -1 WHSV h -1 S Removal W% HC Conversion W % Cu-Zn-Al (1)-1 329 1000 59 22500 28 90 1.2 Table 5 - Oxidation of DBT in toluene solution Catalyst T °C S Content ppmw O 2 /S GHSV h -1 WHSV h -1 S removal W% HC Conversion W % Cu-Zn-Al (1)-1 300 800 80 2600 6 87 2.1 Cu-Zn-Al (2)-2 360 900 139 2900 6 53 3.5 Cu-Zn-Al (1)-3 385 900 120 3700 8 69 3.9 Cu-Zn-Al(1)-4 370 900 95 3200 8 31 2.9 Cu-Zn-Al-Ce(2)-5 * 350 900
  • GHSV refers to the "gas volume rate” (in liters/hour)
  • WHSV weight hourly space velocity: feed rate (Kg/hours) over the weight of the catalyst.
  • O 2 /S refers to the rate at which oxygen was introduced to the material being tested.
  • S and HC refer to "sulfur” and “hydrocarbon,” respectively.
  • model hydrocarbon fuels containing thiophene, DBT, or 4,6DMDBT (both were dissolved in toluene at 0.09 - 0.5 wt.% S) were treated, using the catalysts of the examples, at various conditions, as set forth in Tables 7, 8, and 9 which follow: Table 7- Adsorptive/oxidative desulfurization of thiophene in hydrocarbon Catalyst T, °C S content, wt.
  • Figure 2 presents exemplary data for a feedstream of thiophene in octane at a sulfur concentration of 0.14 wt.%, with sulfur being converted to gaseous SO 2 and COS. The reaction took place over the time period indicated, and temperatures of the reaction (in °C) are given.
  • a commercially available diesel fuel marketed for off road applications was analyzed for sulfur content, using standard techniques.
  • the total sulfur content was determined to be 0.042 wt.%, distributed, for the most part, amongst dibenzothiophene, 4-methyldibenzothiophene, 4, 6-dimethyldibenzothiophene, acenaphthol[1,2-b]thiophene, 1,4,7,-trimethyldibenzothiophene, and 4-ethyl-6-bethyldibenzothiophene.
  • Example 15 The samples of this example and Example 15 were compared via GC-AED analysis. It found that the straight run diesel fuel of the example contained anywhere from 20-40% less sulfur compounds than the initial fuel sample. Sulfur conversion data bear this out.
  • Table 13 The content of DBT, 4-MDBT and 4,6-DMBT in the straight-run diesel fuel before and after the adsorptive/oxidative desulfurization test Compound Content in the initial diesel fuel, ppm Content in the diesel fuel after the test, ppm Conversion of sulfur compound, % DBT 183 121 34 4-DMBT 206 142 31 4,6-DMDBT 516 363 30 *Sulfur conversion in liquid product was calculated from sulfur content measured by GC-AED analysis.
  • Table 15 summarizes the results from 4,6-DMDBT (line #2) and DBT(line #1) desulfurization. As seen, 4,6-DMDBT has a higher tendency to be adsorbed than DBT for the same operating conditions. This is a result of higher ability of 4,6-DMDBT to be oxidized into sulfates and sulfites as compared to DBT, due to the higher electron density of 4,6-DMDBT.
  • the adsorption route involves the formation of sulfates and sulfites that need the addition of more oxygen as compared to the reaction route leading to SOx. This can be done by either reducing the contact time of oxygen or by increasing the oxygen concentration.
  • Table 14 Catalyst T °C S (wt%) O 2 /S GHSV (h -1 ) WHSV (h -1 ) S removal, W% Gas Analysis S removal, W% Liquid Analysis Cu-Zn-Al (1) 280 0.15 38 27430 28 52 39 Cu-Zn-Al (1) 300 0.16 50 2100 6 13 80 Cu-Zn-Al (1) 300 0.43 30 2700 6 13 60 Cu-Zn-Al (1) 326 0.46 30 4160 6 55 60 Cu-Zn-Al (1) 300 0.43 50 3800 6 20 77
  • Table 15 Catalyst T °C S, W% O2/S GHSV, h -1 WHSV, h -1 S removal, W% Gas Analysis S removal, W% Li
  • the catalyst was examined and FTIR data showed that it contained 6.5 wt.% sulfur in the form of sulfates and sulfites, as well as bulk copper sulfide (Cu 1.96 S and Cu 7 S 4 ), as determined by XRD data.
  • the spent catalyst also contained 11.5 wt.% carbon.
  • the catalyst was regenerated by treatment at 350°C for 4 hours with oxygen-containing gas with the oxygen content being increased gradually from 1 vol.% to 20 vol.%. Finally, the sample was calcined at 800°C under air, for 4 hours.
  • the regenerated catalyst had the following chemical composition in wt.%: Cu - 36.0; Zn - 12.1; A1 - 14.2; Na - 0.02.
  • the sulfur and carbon content in the catalyst were less than 0.3 and 0.1 wt.%, respectively.
  • the catalyst had specific surface area 75 m 2 /g, pore volume 0.30 cm 3 /g and prevailing pore diameter equal to 12 nm.
  • the spinel phase exhibited particles with a size distribution of 2-10 nm (HRTEM data), and had a chemical composition Cu 0.3 Zn 0.7 Al 2 O 4 as determined by EDX analysis.
  • Example 17 Another sample of the spent catalyst of Example 17 was regenerated in an alternative method. Specifically, the sample was regenerated by treatment at 400°C with a steam-nitrogen-oxygen mixture for 4 hours. The steam content of the mixture was 10 vol.% and the oxygen content was in the range 1-5 vol.%.
  • the regenerated catalyst was identical in composition to that of Example 19.
  • Example 14 describes using different catalysts to desulfurize different materials.
  • the spent catalyst represented by "Cu-Zn-Al(2),” as used to remove sulfur from DBT in toluene was regenerated. Prior to regeneration, the spent catalyst was determined to contain 2.3 wt.% sulfur, and 7.3 wt.% carbon.
  • the sample was regenerated by treatment under a hydrogen-containing gas mixture (5 vol.% H 2 in nitrogen), with the temperature being increased from 120°C to 530°C at a rate 60-120°C/hr. Finally the sample was hydrotreated at 530°C for 2 hours.
  • a hydrogen-containing gas mixture (5 vol.% H 2 in nitrogen)
  • the regenerated catalyst had the following composition in wt.%:Cu - 26.3; Zn - 15.8; A1 - 22.3.
  • the sulfur and carbon contents were less than 0.5 and 2.0 wt.%, respectively.
  • the catalyst had a specific surface area 70 m 2 /g, pore volume 0.27 cm 3 /g and prevailing pore diameter equal to 11 nm.
  • a second sample of the spent catalyst discussed in Example 21 was regenerated, by treatment at 360°C for 2 hours under a hydrogen-containing gas mixture (5 vol.% H 2 in nitrogen), with the temperature increased from 120°C to 360°C at a rate 60-90°C/hrs. Then, the sample was kept at 350°C under an inert gas for 1 hour and under air flow for 2 hours.
  • a hydrogen-containing gas mixture (5 vol.% H 2 in nitrogen)
  • the regenerated catalyst had the same composition as that of Example 21, and sulfur and carbon content less than 0.5 and 0.4 wt.%.
  • the catalyst had a specific surface area of 75 m 2 /g, a pore volume of 0.33 cm 3 /g and a prevailing pore diameter of 12 nm.
  • This sample was regenerated by high temperature pyrolysis at 760°C under an inert atmosphere, for 4 hours, resulting in calcination.
  • the calcined catalyst had the following composition in wt.%: Cu - 20.9; Zn - 17.1; A1 - 23.9; Ce - 0.5.
  • the sulfur and carbon contents were less than 0.3 and 2.5 wt.% (the carbon was in the form of carbonates), respectively.
  • the catalyst had a specific surface area 70 m 2 /g, pore volume 0.17 cm 3 /g and prevailing pore diameter equal to 8.5 nm.
  • catalytic compositions useful, e.g., in oxidative and/or adsorptive removal of sulfur from gaseous, sulfur containing hydrocarbons, as well as processes for making the compositions, and their use.
  • the catalytic compositions comprise oxides of copper, zinc, and aluminum in defined weight percent ranges, and may also contain cerium oxide.
  • the compositions exhibit an X-ray amorphous oxides phase with highly dispersed oxides of Zn, Cu, and optionally Ce.
  • the compositions contain defined amounts of the metallic oxides.
  • the weight percentages are 5 to less than 20 weight percent zinc oxide, from 10 to 50 weight percent copper oxide, and from 20 to 70 weight percent of aluminum oxide.
  • cerium oxide When cerium oxide is present, its amount can range from 0.1 to 10 wt percent of the composition.
  • the aforementioned structure has a lattice parameter corresponding to spinel, according to HRTEM data and the chemical formula Cu x Zn 1-x Al 2 O 4 , found from EDX analysis which is in accordance with the standard formula for spinels, i.e., "MAl 2 O 4 ,” where "M” signifies a metal or combination of metals.
  • the ZnO and CuO are present as highly dispersed crystals. If cerium oxide is present, it is in particle form, with particles ranging in diameter from 5 nm to 10 nm.
  • X ranges from 0.1 to 0.6, more preferably, from 0.2 to 0.5.
  • compositions preferably are granular in nature, and may be formed into various embodiments such as a cylinder, a sphere, a trilobe, or a quatrolobe, preferably via processes discussed infra .
  • the granules of the compositions preferably have diameters ranging from 1 mm to 4 mm.
  • compositions preferably have specific surface areas ranging from 10 m 2 /g to 100 m 2 /g, more preferably 50 m 2 /g to 100 m 2 /g, with pores ranging from 8 nm to 12 nm, more preferably, 8 nm to 10 nm.
  • the weight percentages are: 20-45 CuO, 10 ⁇ 20 ZnO, and 20-70 Al 2 O 3 , and most preferably 30-45 CuO, 12 ⁇ 20 ZnO, and 20-40 Al 2 O 3 .
  • the catalytic compositions are made by preparing an aqueous solution of the nitrates of Cu, Zn, and Al, and optionally Ce, and then combining this solution with an aqueous alkaline solution which contains NaOH, and/or one or more of (NH 4 ) 2 CO 3 , Na 2 CO 3 and NH 4 HCO 3 .
  • the precipitate may be aged prior to the filtering and washing, as elaborated in the examples.
  • the binder may be, e.g., polyethylene oxide, polyvinyl alcohol, aluminum pseudoboehmite, silica gel, or mixtures thereof.
  • the binder may be added in amounts ranging from about 1 wt% to about 20 wt% of the precipitate, preferably from 1 - 10 wt.% or in the case of hydroxides 3 - 20 wt.%.
  • the resulting mixture may be extruded through, e.g., a forming die, and then dried, preferably at room temperature, for 24 hours, followed by drying at about 100°C for 2-4 hours.
  • the extrusion product is then heated slowly, e.g., by increasing temperatures by 2-5°C every minute until a temperature of 500°C is reached, followed by calcination at 500°C for 2-4 hours.
  • the compositions are used by combining them with a sulfur containing hydrocarbon, in gaseous form, together with an oxygen source, for a time sufficient for at least a portion of the sulfur to be oxidized to, e.g., SO 2 .
  • the oxygen source is preferably pure oxygen, but may be air, or any other oxygen source.
  • the materials recited supra are combined at conditions which include pressure of from 1-30 bars, temperature of from 200°C to 600°C, with a weight hourly space velocity of from 1-20 h -1 , gas hourly space velocity of from 1,000 - 20,000 h -1 , with an oxygen carbon molar ratio of from 0.01 to 0.1, and a molar ratio of oxygen and sulfur of fro m 1 to 150.
  • the pressure ranges from 1-10 bars, most preferably 1-5 bars
  • the temperature is preferably from 250 - 500°C, and is most preferably 300 - 500°C.
  • the gas hourly space velocity is preferably 5,000 - 15,000 h -1 , most preferably 5,000 to 10,000 h -1 , while the preferred molar ration of O 2 /C ranges from 0.02 - 0.1, and most preferably from 0.05 - 0.1, while that of O 2 /S is from 10 - 100, and most preferably, from 20 - 50.
  • the feedstock i.e., the sulfur containing hydrocarbon
  • the feedstock will vary, but preferably is one with a boiling point above 36°C, and even more preferably, above 565°C.
  • the catalytic compositions are used in the form of, e.g., fixed beds, ebullated beds, moving beds, or fluidized beds.
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WO2013015889A1 (en) 2013-01-31
JP2014524836A (ja) 2014-09-25
CN104136116B (zh) 2017-02-08
JP5813228B2 (ja) 2015-11-17
CN104136116A (zh) 2014-11-05
KR101988065B1 (ko) 2019-06-11
US20130028822A1 (en) 2013-01-31
EP2736636A1 (en) 2014-06-04
KR20140079365A (ko) 2014-06-26
US9663725B2 (en) 2017-05-30

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